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Coating Formulation Calculator
Estimate coating usage, gallons needed, cost per project, and formulation adjustments
🎨 Coating formulation calculations • Wet film thickness • Dry film thickness • Solids content • Transfer efficiency
0 gal
Total Gallons Needed (with waste)
0 mils
Wet Film Thickness
0 ft²/gal
Actual Coverage Rate
$0
Material Cost
$0
Total Project Cost (est.)
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⚠️ Important Disclaimer
This coating formulation calculator provides estimates for planning purposes only. Actual coating consumption varies based on substrate porosity, surface profile, application equipment, operator skill, and environmental conditions. Always conduct on-site testing and consult your coating supplier's technical data sheet before finalizing material orders.
This coating formulation calculator provides estimates for planning purposes only. Actual coating consumption varies based on substrate porosity, surface profile, application equipment, operator skill, and environmental conditions. Always conduct on-site testing and consult your coating supplier's technical data sheet before finalizing material orders.
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Coating Formulation Calculations Explained
Understanding coating formulation is essential for accurate material estimation, cost control, and project success. Our calculator uses industry-standard formulas to help you determine exactly how much coating you'll need.
Wet Film Thickness (WFT) = Dry Film Thickness (DFT) ÷ (Solids % ÷ 100)
Theoretical Coverage (ft²/gal) = 1604 ÷ Wet Film Thickness (mils)
Gallons Needed = Surface Area ÷ (Coverage × Transfer Efficiency × (1 − Waste %))
Key Coating Calculation Terms
- Wet Film Thickness (WFT): The thickness of coating as applied (wet). Measured in mils (1 mil = 0.001 inch).
- Dry Film Thickness (DFT): The final thickness after solvents evaporate and coating cures.
- Solids by Volume (SV%): Percentage of coating that remains as solid film after drying.
- Transfer Efficiency (TE%): Percentage of coating that actually reaches the substrate (vs. overspray or waste).
- Theoretical Coverage: 1,604 ft² per gallon at 1 mil dry film thickness (based on 100% solids).
Application Methods & Transfer Efficiency
- Spray (HVLP/Conventional): 50-70% transfer efficiency
- Airless Spray: 60-80% transfer efficiency
- Electrostatic Spray: 70-90% transfer efficiency
- Brush/Roller: 85-95% transfer efficiency (minimal overspray)
- Dip Coating: 80-95% transfer efficiency
How to Use This Calculator
- Step 1: Enter your surface area in square feet
- Step 2: Specify the required dry film thickness (DFT) in mils
- Step 3: Enter the coating's solids by volume percentage (found on product TDS)
- Step 4: Adjust transfer efficiency based on your application method
- Step 5: Add a waste factor for overspray, spills, and uneven application
- Step 6: Enter coating cost and labor rate to estimate total project cost
Coating Types & Typical Solids Content
- Epoxy Coatings: 40-80% solids by volume
- Polyurethane Coatings: 30-70% solids by volume
- Acrylic Latex: 30-45% solids by volume
- High-Build Coatings: 80-100% solids by volume
- Waterborne Coatings: 30-50% solids by volume
- UV Coatings: 95-100% solids by volume
Frequently Asked Questions
- What is the 1,604 constant used for? — 1,604 is the theoretical coverage in square feet per gallon at 1 mil dry film thickness (based on 100% solids).
- How do I calculate wet film thickness? — Divide the dry film thickness by the solids percentage (as a decimal). Example: 2 mil DFT ÷ 0.65 = 3.08 mils WFT.
- What's the difference between volume solids and weight solids? — Volume solids are used for coverage calculations; weight solids are for formulation. Always use volume solids for coverage.
- Why do I need a waste factor? — Coating loss occurs from overspray, spills, equipment cleanup, and uneven application. 10-15% is typical for spray applications.
- How accurate is this calculator? — Provides excellent estimates, but actual usage may vary. Always test on a sample area first.